DESIGN AND FABRICATION OF PORTABLE PNEUMATIC FUEL PUMP

A PROJECT REPORT

Submitted by

PRABHU J (080212100085)

RAJARAJAN N M (080212100097)

SARAVANAKUMAR S (080212100109)

VEERAMANIKANDAN A (080212100128)

in partial fulfilment for the award of the degree

Of

BACHELOR OF ENGINEERING

IN

MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

ANNA UNIVERSITY OF TECHNOLOGY COIMBATORE

COIMBATORE – 641047

June 2011

ACKNOWLEDGEMENT

First and foremost, we thank the Lord almighty for showering his

blessings and lifting us in our all endeavours.

We wish to express our deep sense of gratitude and heartfelt thanks to the

Vice Chancellor Dr. K. Karunakaran, Anna University of Technology

Coimbatore, for providing the efficient lab facilities and internet facilities

which paved the way for the successful completion of the project.

We wish to express our sincere thanks and deep sense of gratitude to the

Registrar Cdr. S. Premchand, Anna University of Technology Coimbatore, for

providing the necessary facilities along with sound moral support to carry out

this project work successfully.

We express our deep gratitude towards our respected Dean Academics,

Dr. M. Saravanakumar, Anna University of Technology Coimbatore, for his

continuous encouragement and support.

We would like to thank, Dr. M. Sakthivel, Head of the Department,

Mechanical Engineering, for giving his various ideas and suggestions which

helped in enhancing the project in efficient way.

We would like to express our sincere thankfulness and deep sense of

gratitude to our guide Dr. K. Sooryaprakash, Assistant Professor, Department

of Mechanical Engineering for giving his full support with encouraging words

and mind which helped in completing this project with interest and to learn

about various techniques.

We would also like to express our sincere thankfulness and deep gratitude

to all our beloved faculty of the Department of Mechanical Engineering.

TABLE OF CONTENTS

CHAPTER NO. TITLE PAGE NO.

ABSTRACT i

LIST OF TABLES ii

LIST OF FIGURES iii

1 INTRODUCTION

1.1 Project Overview 1

1.2 Company Profile 5

2 LITERATURE REVIEW 6

3 OBJECTIVE 7

4 PROJECT DESCRIPTION

4.1 Introduction 8

4.2 Components and Descriptions 13

4.3 Block Diagram 17

4.4 Parts of the Pump 18

4.5 Parts Specifications 23

4.6 Working Principle 27

4.7 Design Calculation 29

4.8 Maintenance 31

4.9 Advantages and Limitations 32

5 BILL OF MATERIALS 33

6 COST ESTIMATION 34

7 CONCLUSION AND FUTURE ENHANCEMENTS

7.1 Conclusion 35

7.2 Future Enhancements 35

8 REFERENCES 36

ABSTRACT

This project “DESIGN AND FABRICATION OF PORTABLE

PNEUMATIC FUEL PUMP” is an outcome of basic instinct to increase the

discharge rate and decrease the time of pumping the fuel from storage barrels to

the machine or equipment especially industries where machineries are placed in

second or third floor.

By utilizing simple pneumatic mechanism, fuel can be pumped especially

with less power consumption and minimum human labour. When compared to

traditional fuel pumping the time taken is also dramatically reduced, as the

discharge rate is increased drastically.

Added advantage in this is portable and occupies less space. It is ideal for

fuel pumping, as no electric field around the fuel pumping area.

This project is of great use to companies where pumping of fuel is

everyday duty, even this project can be used in ration shops.

LIST OF FIGURES

FIGURE NO

TITLEPAGE

NO

4.3.1 BLOCK DIAGRAM OF FUEL PUMP 17

4.4.1 PRESSURE GAUGE 18

4.4.2 AIR HOSE 19

4.4.3 GATE VALVE 21

4.4.4 O RINGS 22

4.5.1 CYLINDER HEAD 23

4.5.2 CYLINDER 24

4.5.3 ONE WAY VALVE 24

4.5.4 SUCTION PIPE 25

4.5.5 ISOMETRIC VIEW OF PNEUMATIC FUEL PUMP 26

4.6.1 FUNCTION CHART 28

LIST OF TABLES

TABLE NO TITLE PAGE NO

1 BILL OF MATERIALS 33

2 COST ESTIMATION 34

CHAPTER 1

INTRODUCTION

1.1 PROJECT OVERVIEW

In the pursuit of excellence, the manufacturing industries are seeking now in a new

technology to improve productivity, quality of the product and reduce product cost. The cited

subjects are seriously discussed in these days.

Most of the manufacturing industries use centrifugal pumps for pumping fuel from

barrels to the required location. The discharge rate of centrifugal pump is low. The discharge

head has also some limitations which restrict the use of centrifugal pump where high head is

required.

As a fuel pump, the centrifugal pump is always risky because of electric motor placed

just behind the impeller, which may lead to fire accidents.

Hence having this in mind, usage of reciprocating pump instead of centrifugal pump

looked like the best alternate. Rather than keeping the idea in mind we brought it to reality.

We tested the performance of both the pumps.

In this work a double acting reciprocating pump is used as fuel pump.

PNEUMATICS

The word ‘pneuma’ comes from Greek and means breather wind. The word

pneumatics is the study of air movement and its phenomena is derived from the word

pneuma. Today pneumatics is mainly understood to means the application of air as a working

medium in industry especially the driving and controlling of machines and equipment.

Pneumatics has for some considerable time between used for carrying out the

simplest mechanical tasks in more recent times has played a more important role in the

development of pneumatic technology for automation.

Pneumatic systems operate on a supply of compressed air which must be made

available in sufficient quantity and at a pressure to suit the capacity of the system. When the

pneumatic system is being adopted for the first time, however it wills indeed the necessary to

deal with the question of compressed air supply.

The key part of any facility for supply of compressed air is by means using

reciprocating compressor. A compressor is a machine that takes in air, gas at a certain

pressure and delivered the air at a high pressure.

Compressor capacity is the actual quantity of air compressed and delivered and the

volume expressed is that of the air at intake conditions namely at atmosphere pressure and

normal ambient temperature.

The compressibility of the air was first investigated by Robert Boyle in 1962 and that

found that the product of pressure and volume of a particular quantity of gas.

The usual written as

PV = C (or) P1V1 = P2V2

In this equation the pressure is the absolute pressured which for free is about 14.7 Psi

and is of courage capable of maintaining a column of mercury, nearly 30 inches high in an

ordinary barometer. Any gas can be used in pneumatic system but air is the mostly used

system now a days.

SELECTION OF PNEUMATICS

Mechanization is broadly defined as the replacement of manual effort by mechanical

power. Pneumatic is an attractive medium for low cost mechanization particularly for

sequential (or) repetitive operations. Many factories and plants already have a compressed air

system, which is capable of providing the power (or) energy requirements and the control

system (although equally pneumatic control systems may be economic and can be

advantageously applied to other forms of power).

The main advantage of an all pneumatic system are usually economic and simplicity

the latter reducing maintenance to a low level. It can also have outstanding advantages in

terms of safety.

PRODUCTION OF COMPRESSED AIR

Pneumatic systems operate on a supply of compressed air, which must be made

available. In sufficient quantity and at a pressure to suit the capacity of the system. When

pneumatic system is being adopted for the first time, however it wills indeed the necessary to

deal with the question of compressed air supply. The key part of any facility for supply

of compressed air is by means using reciprocating compressor. A compressor is a machine

that takes in air, gas at a certain pressure and delivered the air at a high pressure.

Compressor capacity is the actual quantity of air compressed and delivered and the

volume expressed is that of the air at intake conditions namely at atmosphere pressure and

normal ambient temperature. Clean condition of the suction air is one of the factors, which

decides the life of a compressor. Warm and moist suction air will result in increased

precipitation of condense from the compressed air. Compressor may be classified in two

general types.

1. Positive displacement compressor.

2. Turbo compressor

Positive displacement compressors are most frequently employed for compressed

air plant and have proved highly successful and supply air for pneumatic control application.

The types of positive compressor

1. Reciprocating type compressor

2. Rotary type compressor

Turbo compressors are employed where large capacity of air required at low

discharge pressures. They cannot attain pressure necessary for pneumatic control

application unless built in multistage designs and are seldom encountered in pneumatic

service.

ROTARY TYPE COMPRESSORS

Rotary screw compressors use two meshing helical screws, known as rotors, to

compress the gas. In a dry running rotary screw compressor, timing gears ensure that the

male and female rotors maintain precise alignment. In an oil-flooded rotary screw

compressor, lubricating oil bridges the space between the rotors, both providing a hydraulic

seal and transferring mechanical energy between the driving and driven rotor. Gas enters at

the suction side and moves through the threads as the screws rotate. The meshing rotors force

the gas through the compressor, and the gas exits at the end of the screws.

RECIPROCATING COMPRESSORS

Built for either stationary (or) portable service the reciprocating compressor is by far

the most common type. Reciprocating compressors lap be had is sizes from the smallest

capacities to deliver more than 500 m³/

min. In single stage compressor, the air pressure may be of 6 bar machines discharge of

pressure is up to 15 bars. Discharge pressure in the range of 250 bars can be obtained with

high pressure reciprocating compressors that of three & four stages.

Single stage and 1200 stage models are particularly suitable for pneumatic

applications, with preference going to the two stage design as soon as the discharge pressure

exceeds 6 bar, because it in capable of matching the performance of single stage machine at

lower costs per driving powers in the range.

1.2 COMPANY PROFILE

NAME : PERFECT POLY COATS

ADDRESS : S.F No. 408 / 1C,

PRICOL PLANT I,

Ramakrishna nagar,

Jothipuram Post

Coimbatore - 641047

NATURE OF WORK : Painting automobile components

M/S. Perfect poly coats is the painting shop where most of the PRICOL manufactured

components like clusters, speedometer consoles etc., are painted. This is the only painting

shop which runs under PRICOL.

It supplies products to the companies like Toyota, Ashok Leyland, TVS, Yamaha,

Mahindra & Mahindra etc.,

CHAPTER 2

LITERATURE REVIEW

The following solutions are drawn by referring various national and international

journals in context with the existing problem definition.

According to European Patent EP0398209 (Reciprocating oil pump), an

existing idea was identified. It works on a reciprocating pump providing oil

for low pressure, self-contained oil-filled cables. The pressure head we

required for our work was yet higher than the existing patent and large

changes are needed on the outlet valve arrangements.

An international journal titled “Design and Experimental Analyses of Small-

flow High-head centrifugal-vortex Pump for Gas-Liquid Two-phase Mixture”

proposed an idea relevant to the current issue, but portability could not be

achieved. Also, centrifugal pumps are operated by electrical means but in our

system pneumatic source should only be used.

Based on an international journal titled “Analysis of gear pumps used to pump

high density oils”, the idea of using a gear pump for our work was revived.

This idea was aborted due to insufficient discharge rate and high cost of the

equipment.

With reference to a United States Patent 6685443 (Pneumatic reciprocating

pump) the idea of using a pneumatically actuated pump was considered.

Hence the pump needed electrical source after actuation, the idea was ignored.

Based on a United States Patent 5158439 (Pneumatic pumping device) which

proposed an idea about a pneumatic pump for pumping acids, this pump can

be used but the density of operating fluid i.e, Diesel was much higher.

CHAPTER 3

OBJECTIVE

The primary objective of our work is to set up a pumping arrangement to pump diesel

for a heating oven in a painting shop. Diesel is used as the fuel for the oven and hence it has

to be pumped to an overhead storage tank from barrels at the ground level. The main

concerns involved were

The pump should be fire proof in order to avoid any fire accidents. The

internal atmosphere of the painting shop contains a considerable amount of

highly inflammable substances like thinner vapours.

The pump must be portable. There are four overhead tanks where the fuel has

to be pumped separately.

Electric motors cannot be used as the driving source due to the increased risk

of fire accidents.

It was better to use pneumatic source as the primary source of power. It was

the highly available source in the paint shop as it was used throughout the

painting process for spraying and drying procedures.

Thus through our search for a suitable way satisfying all the above concerns we

decided to work on this project which we found simple and economical.

CHAPTER 4

PROJECT DESCRIPTION

4.1 INTRODUCTION

Positive displacement pumps

A positive displacement pump causes a fluid to move by trapping a fixed amount of it

then forcing (displacing) that trapped volume into the discharge pipe.

A positive displacement pump has an expanding cavity on the suction side and a

decreasing cavity on the discharge side. Liquid flows into the pump as the cavity on the

suction side expands and the liquid flows out of the discharge as the cavity collapses. The

volume is constant given each cycle of operation.

Positive displacement rotary pumps are pumps that move fluid using the principles of

rotation. The vacuum created by the rotation of the pump captures and draws in the liquid.

Rotary pumps are very efficient because they naturally remove air from the lines, eliminating

the need to bleed the air from the lines manually.

Positive displacement rotary pumps also have their weaknesses. Because of the nature

of the pump, the clearance between the rotating pump and the outer edge must be very close,

requiring that the pumps rotate at a slow, steady speed. If rotary pumps are operated at high

speeds, the fluids will cause erosion. Rotary pumps that experience such erosion eventually

show signs of enlarged clearances, which allow liquid to slip through and reduce the

efficiency of the pump.

Positive displacement rotary pumps can be grouped into three main types. Gear

pumps are the simplest type of rotary pumps, consisting of two gears laid out side-by-side

with their teeth enmeshed. The gears turn away from each other, creating a current that traps

fluid between the teeth on the gears and the outer casing, eventually releasing the fluid on the

discharge side of the pump as the teeth mesh and go around again. Many small teeth maintain

a constant flow of fluid, while fewer, larger teeth create a tendency for the pump to discharge

fluids in short, pulsing gushes.

Screw pumps are a more complicated type of rotary pumps, featuring two or three

screws with opposing thread —- that is, one screw turns clockwise, and the other

counterclockwise. The screws are each mounted on shafts that run parallel to each other; the

shafts also have gears on them that mesh with each other in order to turn the shafts together

and keep everything in place. The turning of the screws, and consequently the shafts to which

they are mounted, draws the fluid through the pump. As with other forms of rotary pumps,

the clearance between moving parts and the pump's casing is minimal.

Moving vane pumps are the third type of rotary pumps, consisting of a cylindrical

rotor encased in a similarly shaped housing. As the rotor turns, the vanes trap fluid between

the rotor and the casing, drawing the fluid through the pump.

Reciprocating - type

Positive displacement pumps have an expanding cavity on the suction side and a

decreasing cavity on the discharge side. Liquid flows into the pumps as the cavity on the

suction side expands and the liquid flows out of the discharge as the cavity collapses. The

volume is constant given each cycle of operation.

The positive displacement pumps can be divided into two main classes

Reciprocating

Rotary

The positive displacement principle applies to the following pumps. They are,

Rotary lobe pump

Progressive cavity pump

Rotary gear pump

Piston pump

Diaphragm pump

Screw pump

Gear pump

Hydraulic pump

Vane pump

Regenerative (peripheral) pump

Peristaltic pump

Positive displacement pumps, unlike centrifugal or roto-dynamic pumps, will produce

the same flow at a given speed (RPM) no matter what the discharge pressure. Positive

displacement pumps are "constant flow machines"

A positive displacement pump must not be operated against a closed valve on the

discharge side of the pump because it has no shut-off head like centrifugal pumps. A positive

displacement pump operating against a closed discharge valve, will continue to produce flow

until the pressure in the discharge line are increased until the line bursts or the pump is

severely damaged – or both.

A relief or safety valve on the discharge side of the positive displacement pump is

therefore necessary. The relief valve can be internal or external. The pump manufacturer

normally has the option to supply internal relief or safety valves. The internal valve should in

general only be used as a safety precaution, an external relief valve installed in the discharge

line with a return line back to the suction line or supply tank is recommended.

Reciprocating pumps

Typical reciprocating pumps are

Plunger pumps

Diaphragm pumps

A plunger pump consists of a cylinder with a reciprocating plunger in it. The suction

and discharge valves are mounted in the head of the cylinder. In the suction stroke the

plunger retracts and the suction valves open causing suction of fluid into the cylinder. In the

forward stroke the plunger pushes the liquid out of the discharge valve.

With only one cylinder the fluid flow varies between maximum flow when the

plunger moves through the middle positions, and zero flow when the plunger is at the end

positions. A lot of energy is wasted when the fluid is accelerated in the piping system.

Vibration and "water hammer" may be a serious problem. In general the problems are

compensated for by using two or more cylinders not working in phase with each other.

In diaphragm pumps, the plunger pressurizes hydraulic oil which is used to flex a

diaphragm in the pumping cylinder. Diaphragm valves are used to pump hazardous and toxic

fluids.

An example of the piston displacement pump is the common hand soap pump.

Gear pump

This uses two meshed gears rotating in a closely fitted casing. Fluid is pumped

around the outer periphery by being trapped in the tooth spaces. It does not travel back on the

meshed part, since the teeth mesh closely in the centre. Widely used on car engine oil pumps.

it is also used in various hydraulic power packs..

Progressing cavity pump

Widely used for pumping difficult materials such as sewage sludge contaminated

with large particles, this pump consists of a helical shaped rotor, about ten times as long as its

width. This can be visualized as a central core of diameter x, with typically a curved spiral

wound around of thickness half x, although of course in reality it is made from one casting.

This shaft fits inside a heavy duty rubber sleeve, of wall thickness typically x also. As the

shaft rotates, fluid is gradually forced up the rubber sleeve. Such pumps can develop very

high pressure at quite low volumes.

Roots-type pumps

The low pulsation rate and gentle performance of this Roots-type positive

displacement pump is achieved due to a combination of its two 90° helical twisted rotors, and

a triangular shaped sealing line configuration, both at the point of suction and at the point of

discharge. This design produces a continuous and non-vorticuless flow with equal volume.

Some applications are:

High capacity industrial air compressors

Roots Type Superchargers on internal combustion engines.

A brand of civil defense siren, the Federal Signal Corporation's Thunderbolt.

Peristaltic pump

A peristaltic pump is a type of positive displacement pump used for pumping a

variety of fluids. The fluid is contained within a flexible tube fitted inside a circular pump

casing (though linear peristaltic pumps have been made). A rotor with a number of "rollers",

"shoes" or "wipers" attached to the external circumference compresses the flexible tube. As

the rotor turns, the part of the tube under compression closes (or "occludes") thus forcing the

fluid to be pumped to move through the tube. Additionally, as the tube opens to its natural

state after the passing of the cam ("restitution") fluid flow is induced to the pump. This

process is called peristalsis and is used in many biological systems such as

the gastrointestinal tract.

Reciprocating-type pumps

Reciprocating pumps are those which cause the fluid to move using one or more

oscillating pistons, plungers or membranes (diaphragms).

Reciprocating-type pumps require a system of suction and discharge valves to ensure

that the fluid moves in a positive direction. Pumps in this category range from having

"simplex" one cylinder, to in some cases "quad" four cylinders or more. Most reciprocating-

type pumps are "duplex" (two) or "triplex" (three) cylinder. Furthermore, they can be either

"single acting" independent suction and discharge strokes or "double acting" suction and

discharge in both directions. The pumps can be powered by air, steam or through a belt drive

from an engine or motor. This type of pump was used extensively in the early days of steam

propulsion (19th century) as boiler feed water pumps. Reciprocating pumps are now typically

used for pumping highly viscous fluids including concrete and heavy oils, and special

applications demanding low flow rates against high resistance.

Compressed-air-powered double-diaphragm pumps

One modern application of positive displacement diaphragm pumps is compressed-

air-powered double-diaphragm pumps. Run on compressed air these pumps are intrinsically

safe by design, although all manufacturers offer ATEX certified models to comply with

industry regulation. Commonly seen in all areas of industry from shipping to processing,

Graco, SandPiper, Wilden Pumps or ARO are generally the larger of the brands. They are

relatively inexpensive and can be used for almost any duty from pumping water out of bunds,

to pumping hydrochloric acid from secure storage (dependent on how the pump is

manufactured – elastomers / body construction). Lift is normally limited to roughly 6m

although heads can reach almost 200 Psi.

4.2 COMPONENTS AND DESCRIPTION

PNEUMATIC CONTROL COMPONENT

Pneumatically controlling valves are valves that control the flow of pressurized air.

Another medium such as water (hydraulics) or electricity, for example, may be used to

control the valves.

Pneumatic cylinder

Pneumatic cylinders (sometimes known as air cylinders) are mechanical

devices which utilize the power of compressed gas to produce a force in a

reciprocating linear motion.  Like hydraulic cylinders, pneumatic cylinders use the stored

potential energy of a fluid, in this case compressed air, and convert it into kinetic energy as

the air expands in an attempt to reach atmospheric pressure. This air expansion forces

a piston to move in the desired direction. The piston is a disc or cylinder, and the piston rod

transfers the force it develops to the object to be moved. Engineers prefer to use pneumatics

sometime because they are quieter, cleaner, and do not require large amounts or space for

fluid storage.

An air cylinder is an operative device in which the state input energy of compressed

air i.e. pneumatic power is converted in to mechanical output power, by reducing the

pressure of the air to that of the atmosphere.

Single acting cylinder

Single acting cylinder is only capable of performing an operating medium in only one

direction. Single acting cylinders equipped with one inlet for the operating air pressure, can

be production in several fundamentally different designs.

Single cylinders develop power in one direction only. Therefore no heavy control

equipment should be attached to them, which requires to be moved on the piston return stoke

single action cylinder requires only about half the air volume consumed by a double acting

for one operating cycle.

Double acting cylinders:

A double acting cylinder is employed in control systems with the full pneumatic

cushioning and it is essential when the cylinder itself is required to retard heavy messes. This

can only be done at the end positions of the piston stock. In all intermediate position a

separate externally mounted cushioning derive most be provided with the damping feature.

The normal escape of air is out off by a cushioning piston before the end of the stock is

required. As a result the sit in the cushioning chamber is again compressed since it cannot

escape but slowly according to the setting made on reverses. The air freely enters the

cylinder and the piston stokes in the other direction at full force and velocity.

Parts of Pneumatic Cylinder

Piston

A piston is a component of reciprocating engines, reciprocating pumps, gas

compressors and pneumatic cylinders, among other similar mechanisms. It is the moving

component that is contained by a cylinder and is made gas-tight by piston rings. In an engine,

its purpose is to transfer force from expanding gas in the cylinder to the crankshaft via

a piston rod and/or connecting rod. In a pump, the function is reversed and force is

transferred from the crankshaft to the piston for the purpose of compressing or ejecting

the fluid in the cylinder. In some engines, the piston also acts as a valve by covering and

uncovering ports in the cylinder wall.

In other words, the piston can be defined as a cylindrical member of certain length

which reciprocates inside the cylinder. The diameter of the piston is slightly less than that of

the cylinder bore diameter and it is fitted to the top of the piston rod. It is one of the

important parts which convert the pressure energy into mechanical power.

The piston is equipped with a ring suitably proportioned and it is relatively soft

rubber which is capable of providing good sealing with low friction at the operating pressure.

The purpose of piston is to provide means of conveying the pressure of air inside the cylinder

to the piston of the oil cylinder.

Generally piston is made up of

Aluminium alloy-light and medium work.

Brass or bronze or CI-Heavy duty.

The piston is double acting type. The piston moves forward when the high-pressure

air is turned from the right side of cylinder. The piston moves backward when high pressure

acts on the piston from the left side of the cylinder. The piston should be as strong and rigid

as possible.

The efficiency and economy of the machine primarily depends on the working of the

piston. It must operate in the cylinder with a minimum of friction and should be able to

withstand the high compressor force developed in the cylinder and also the shock load during

operation.

The piston should posses the following qualities.

a. The movement of the piston not creates much noise.

b. It should be frictionless.

c. It should withstand high pressure.

Piston Rod

The piston rod is circular in cross section. It connects piston with piston of other

cylinder. The piston rod is made of mild steel ground and polished. A high finish is

essential on the outer rod surface to minimize wear on the rod seals. The piston rod is

connected to the piston by mechanical fastening. The piston and the piston rod can be

separated if necessary.

One end of the piston rod is connected to the bottom of the piston. The other end of

the piston rod is connected to the other piston rod by means of coupling. The piston

transmits the working force to the oil cylinder through the piston rod. The piston rod is

designed to withstand the high compressive force. It should avoid bending and withstand

shock loads caused by the cutting force. The piston moves inside the rod seal fixed in the

bottom cover plate of the cylinder. The sealing arrangements prevent the leakage of air from

the bottom of the cylinder while the rod reciprocates through it.

Cylinder Cover Plates

The cylinder should be enclosed to get the applied pressure from the compressor and

act on the pinion. The cylinder is thus closed by the cover plates on both the ends such that

there is no leakage of air. An inlet port is provided on the top cover plate and an outlet ports

on the bottom cover plate. There is also a hole drilled for the movement of the piston.

Cylinder Mounting Plates:

It is attached to the cylinder cover plates and also to the carriage with the help of ‘L’

bends and bolts.

Control valve:

Various types of control valves are used to regulate, control and monitor the air

energy for control of direction pressure, flow, etc.

Pneumatic energy is regulated and controlled by pneumatic valves. Functionally

valves are divided into four major groups.

Direction Control

Flow Control

Solenoid is another name for an electromagnet. Direction control valves are very

often actuated by electromagnets. An electromagnet is a temporary magnet. A magnetic

force is developed in an electromagnet when electrical current passes through it and force

drops down as soon as it is de energized.

This electromagnet is commonly termed as solenoid. The proper working of a

solenoid operated valve depends on the reliability of the electromagnets.

It ensures

Quick and sure action

Long life.

Easy maintenance.

Less wastage of energy.

4.3 BLOCK DIAGRAM

Fig. 4.3.1 Fuel Pump

The block diagram, as shown in the fig 4.3.1, shows the arrangement of the portable

pneumatic pump. This model is the actual output of this study.

AIR ADJUSTMENT SCREW

AIR INLET

PISTION ARRANGEMENT

FUEL DELIVERY

ONE WAY VALVE

SUCTION PIPE

PRE FILTER

4.4 PARTS OF THE FUEL PUMP

The following are the parts of the fuel pump,

Pressure gauge

Air adjustment screw

Cylinder

Suction pipe

Filter

Air hose

Locknut

Grease nipple

¼ inch gate valve

O Rings

Cylinder head

Tube couplers

Pressure gauge

Fig 4.4.1 pressure gauge

Instruments used to measure pressure are called pressure gauges or vacuum gauges

shown in the fig 4.4.1. A manometer could also be referring to a pressure measuring

instrument, usually limited to measuring pressures near to atmospheric. The term manometer

is often used to refer specifically to liquid column hydrostatic instruments. A vacuum gauge

is used to measure the pressure in a vacuum—which is further divided into two

subcategories, high and low vacuum (and sometimes ultra-high vacuum). The applicable

pressure range of many of the techniques used to measure vacuums has an overlap.

Filter

A pneumatic filter is a device which removes contaminants from a compressed air

stream. This can be done using a number of different techniques, from using a "media" type

that traps particulates, but allows air to pass through to a venturi, to a membrane that only

allows air to pass through.

Air hose

Air hose is shown in the fig 4.4.2. Air hoses are used in underwater diving, such as

scuba diving, to carry air from the surface or from air tanks or diving pumps to the diver. Air

hoses are therefore a necessary part of standard diving dress and any type of surface supplied

diving equipment. They are an essential part of scuba diving equipment, used to deliver

pressurised air from the first stage of a diving regulator to the other components.

Fig 4.4.2 Air hose

Air hoses are used between locomotives and railroad cars for their brakes, and are

also used between those tractors and semi-trailers which use air brakes.

Locknut

A locknut, also known as a lock nut, locking nut, prevailing torque nut, stiff nut or

elastic stop nut, is a nut that resists loosening under vibrations and torque. Elastic stop nuts

and prevailing torque nuts are of the particular type where some portion of the nut deforms

elastically to provide a locking action.

Grease fitting

A grease fitting, grease nipple, Zerk fitting, or Alemite fitting is a metal fitting used

in mechanical systems to feed lubricants, usually lubricating grease, under moderate to high

pressure, into a bearing using a grease gun. The fitting is permanently installed by a threaded

connection, leaving a nipple connection that the grease gun attaches to. The pressure supplied

by the grease gun forces a small captive bearing ball in the nipple to move back against the

force of its retaining spring. The arrangement is thus essentially a valve that opens under

pressure to allow lubricant to pass through a channel and be forced into the voids of the

bearing. When the pressure ceases, the ball returns to its closed position.

The ball excludes dirt intrusion and functions as a check valve to prevent grease

escaping back out of the nipple. The ball is almost flush with the surface of the nipple so it

can be wiped clean to reduce the amount of debris carried with the grease into the bearing.

The convex shape of the fitting allows the concave tip of the grease gun to seal against the

nipple easily from many angles, yet with a sufficiently tight seal to force the pressured

greased to move the ball and enter the fitting, rather than simply oozing past this temporary

annular (ring-shaped) seal. Grease nipples are commonly made from zinc-plated steel,

stainless steel, or brass.

Gate valve

A gate valve, also known as a sluice valve, is a valve that opens by lifting a round or

rectangular gate/wedge out of the path of the fluid as shown in the fig 4.4.2. The distinct

feature of a gate valve is the sealing surfaces between the gate and seats are planar, so gate

valves are often used when a straight-line flow of fluid and minimum restriction is desired.

The gate faces can form a wedge shape or they can be parallel. Typical gate valves should

never be used for regulating flow, unless they are specifically designed for that purpose. On

opening the gate valve, the flow path is enlarged in a highly nonlinear manner with respect to

percent of opening. This means that flow rate does not change evenly with stem travel. Also,

a partially open gate disk tends to vibrate from the fluid flow. Most of the flow change

occurs near shutoff with a relatively high fluid velocity causing disk and seat wear and

eventual leakage if used to regulate flow. Typical gate valves are designed to be fully opened

or closed. When fully open, the typical gate valve has no obstruction in the flow path,

resulting in very low friction loss.

Fig 4.4.3 Gate valve

O Rings

An O-ring, also known as a packing, or a toric joint, is a mechanical gasket in the

shape of a torus; it is a loop of elastomer with a disc-shaped cross-section, designed to be

seated in a groove and compressed during assembly between two or more parts, creating a

seal at the interface as shown in the fig 4.4.4. The O-ring may be used in static applications

or in dynamic applications where there is relative motion between the parts and the O-ring.

Dynamic examples include rotating pump shafts and hydraulic cylinder pistons. O-rings are

one of the most common seals used in machine design because they are inexpensive, easy to

make, reliable, and have simple mounting requirements.

Fig 4.4.4 O rings

4.5 PARTS SPECIFICATION

CYLINDER HEAD

LENGTH : 60 mm

DIAMETER : 70 mm

MATERIAL : Aluminium die casting

DESCRIPTION : It is an aluminium cast block having one inlet, outlet

and relief valve. It is placed above the cylinder

Fig. 4.5.1. Cylinder Head

DOUBLE ACTING CYLINDER

LENGTH : 140 mm

DIAMETER : 85 mm

MATERIAL : Galvanized iron

DESCRIPTION : The double acting cylinder is made up of galvanised

iron. It is fitted just above the pump head

Fig.4.5.2 Cylinder

ONE WAY VALVE

LENGTH : 52 mm

DIAMETER : 48 mm

MATERIAL : Mild steel

DESCRIPTION : It is made up of cast iron used to connect the suction

pipe and piston cylinder. Internal thread is provided

for fastening.

Fig.4.5.3. One Way Valve

SUCTION PIPE

LENGTH : 888 mm

DIAMETER : 27 mm

MATERIAL : Galvanised iron

DESCRIPTION : It is made up of galvanised iron material. V – Notch

is provided at the end of the suction pipe for effective

suction.

Fig.4.5.4. Suction Pipe

PRESSURE GAUGE

RANGE : 1 – 10 bar

DESCRIPTION : It is used monitor the operating pressure. It is directly

connected to the inlet pipe just after the compressor

FILTER

LENGTH : 30 mm

MATERIAL : Iron filter (Copper coated)

DESCRIPTION : It is cone shaped which helps to filter the fuel from

foreign materials, debris and dusts. It is fitted in the

end of the suction pipe.

AIR HOSE

LENGTH : 3000 mm

DIAMETER : 8 mm

MATERIAL : Nylon

DESCRIPTION : It is used to connect the compressor to the pump inlet

The isometric view of the portable pneumatic pump is shown in the fig 4.5.5.

Fig.4.5.5 Isometric View of pneumatic fuel pump

4.6 WORKING PRINCIPLE

Initially starting with air compresses, its function is to compress air from a low inlet pressure

(usually atmospheric) to a higher pressure level. This is an accomplished by reducing the volume of

the air.

Air compressors are generally positive displacement units and are either of the reciprocating

piston type or the rotary screw or rotary vane types. The air compressor used here is a typically small

sized, two-stage compressor unit. It also consists of a compressed air tank, electric rotor and pulley

drive, pressure controls and instruments for quick hook up and use. The compressor is driver by a

10HP motor and designed to operate in 145 – 175 PSI range. If the pressure exceeds the designed

pressure of the receiver a release value provided releases the excesses air and thus stays a head of any

hazards to take place.

The stored air from compressor is passed through an air fitter where the compressed air is

filtered from the fine dust particles. However, before the suction of air into compressor a filter

process take place, but not sufficient to operate in the circuit here the filter is used.

Then having a pressure regulator where the desired pressure to the operated is set. Here a

variable pressure regulator is adopted.

Through a variety of direction control value are available, a hand operated solenoid Valve

with control unit is applied.

The solenoid valve used here is 5 ports, 3 positions. There are two exhaust ports, two outlet

ports and one inlet port. In two extreme positions only the directions can be changed while the

Centro ore is a neutral position and no physical changes are incurred.

The 2 outlet ports are connected to an actuator (Cylinder). The pneumatic activates is a

double acting, single rod cylinder. The cylinder output is coupled to further purpose. The piston end

has an air horning effect to prevent sudden thrust at extreme ends.

Fig. 4.6.1. Function Chart

The function chart, shown in the fig 4.6.1 shows the working of the pump. The

compressed air from the compressor is passed into the pump head which moves the double

acting cylinder. This makes the other side of the piston to suck fuel from suction valve and

send it to the outlet valve.

PRINCIPLE:

The compressed air from the compressor reaches the solenoid valve. The solenoid

valve changes the direction of flow according to the signals from the timing device.

The compressed air pass through the solenoid valve and it is admitted into the front

end of the cylinder block. The air pushes the piston for the cutting stroke. At the end

of the cutting stroke air from the solenoid valve reaches the rear end of the cylinder

DOUBLE ACTING CYLINDER

ONE WAY VALVE

FUEL FROM BARREL

SUCTION PIPE

FUEL OUT

PISTON

PUMP HEAD

COMPRESSOR AIR

block. The pressure remains the same but the area is less due to the presence of

piston rod. This exerts greater pressure on the piston, pushing it at a faster rate thus

enabling faster return stroke.

The non-return valve is fixed to the hydraulic cylinders two side (Four numbers).

The stroke length of the piston can be changed by making suitable adjustment in the

timer.

4.7 DESIGN CALCULATION

Single acting reciprocating pump

Diameter = 85 mm = 0.085 m

Length = 100 mm = 0.1 m

Area

The area of the cylinder,

A = (π /4)* d2

= (π /4)*(0.0852)

= 5.674*10-3 m2

Theoretical Volume/stroke

The volume of the cylinder,

V = A*L m3

= 5.674*10-3*0.1

=5.674*10-4 m3

Number of delivery

One stroke/sec = N/60

N = 60 rpm

Theoretical Discharge Qt

The theoretical discharge of the pump is,

Qt =A*L*N/60

=(5.674*10-3*0.1*60)/60

=5.674*10-4 m3 s-1

= 5.674*10-4*1000

= 0.5674 litre/sec

= 0.5674*3600

= 2042.82 litre/hour

Calculation Verification

The output of the pump is then verified by practical method. The results are given

below,

10 Sec = 5 litre

1 min = 30 litre

1 sec = 0.5 litre.

Thus the values are calculated with reference to standard formulae and the theoretical design values are calculated above. The actual output of the pump is also noted by experiments.

4.8 MAINTENANCE

Maintenance

It is the activity carried to increase the life and performance of the pumps.

Types of Maintenance

1. Preventive maintenance

2. Breakdown maintenance

3. Schedule maintenance

Preventive maintenance

It is carried out regularly say every day, before and after the pump is operated.

Breakdown maintenance

It is done only after the pump stops working completely.

Schedule maintenance

It is carried in routine as per the schedule. It is carried out periodically.

The following are the maintenance which are done in order to avoid breakdown of the

pump,

Lubrication

Periodic inspection

Adjustment of parts

Cleaning

Periodic overhauling

Repair and replacement

4.9 ADVANTAGES AND LIMITATIONS

4.9.1 ADVANTAGES

Even if all the other pumps are similar in use the Pneumatic water pump is more

advantageous than the other pumps.

1. This is of compact in size

2. Less Maintenance is enough

3. The oil or water pumped is of higher pressure

4. Quite running and smooth operation is achieved.

5. Higher efficiency

6. Full efficient positive displacement pump

7. Effective working principle

8. It does not have any Prime mover, like electric motor related to the unit.

9. As the air is freely available, we can utilize the air to pumping the water and

hence it is economical.

10. Less Maintenance

4.9.2 LIMITATIONS

1. It is costlier than the other types of pump because of compressor unit.

2. Less efficiency when compressed to other device.

3. Leakage of air affects the working of the unit.

CHAPTER 5

BILL OF MATERIALS

S.NO PARTS MATERIALS QUANTITY

1 PRESSURE GAUGE STEEL PLATE 1

2 AIR ADJUSTMENT SCREW MILD STEEL 1

3 PISTON MILD STEEL 1

4 CYLINDER GALVANISED IRON 1

5 SUCTION PIPE GALVANISED IRON 1

6 FILTER IRON FILTER 1

7 PISTON ROD MILD STEEL 1

8 HOSE NYLON 2

9 GREASE NIBBLE ALUMINIUM CASTING 1

10 GATE VALVE GALVANISED IRON 1

11 CONNECTING PIN BRASS 1

12 ONE WAY VALVE MILD STEEL 2

13 ORINGS RUBBER 3

14 TUBE COUPLER MILD STEEL 1

15 LOCK NUT BRASS 1

Table 2. Bill of Materials

CHAPTER 6

COST ESTIMATION

S.NO NAME OF THE EQUIPMENT NO OF QUANTITYCOST in

(Rupees)

1 PRESSURE GAUGE 1 250

2 AIR ADJUSTMENT SCREW 1 150

3 PISTON 1 1500

4 CYLINDER 1 350

5 SUCTION PIPE 1 375

6 FILTER 1 150

7 PISTON ROD 1 125

8 HOSE 2 225

9 LOCK NUT 1 50

10 GREASE NIPPLE 1 350

11 ¼ INCH GATE VALVE 1 240

12 OUTLET HOSE 1 90

13 CONNECTING PIN 1 75

14 BALLS AND ONE WAY VALVE 2 450

15 ORINGS 3 125

16 CYLINDER HEAD 1 1225

17 TUBE COUPLING 1 30

18 SPOOL VALVE 1 500

TOTAL 6250

Table 3. Cost Estimation

CHAPTER 7

CONCLUSION & FUTURE ENHANCEMENTS

7.1 CONCLUSION

In this pneumatic fuel pump variable speeds can be obtained by adjusting the pressure

of the compressed air. Since the mechanism is so simple and versatile it can be handled by

any operator, construction of the unit is very simple. Handling the machine is easy and

smooth operation is achieved. This pump also provides fire proof pumping. This increases

fuel discharge and reduces human effort & operating time. The main feature of this pump is,

it is portable.

7.2 FUTURE ENHANCEMENTS

In this pump, an accumulator can be attached. This attachment of accumulator

provides constant discharge.

The diameter of the outlet pipe can be decreased to increase the head.

REFERENCES

Antonio Esposito - Fluid power with application. Prentice hall of India private

limited, 1980.

Bolton,W., - Pneumatic and hydraulic systems, Butterworth-Heinemann, Jordan Hill,

Oxford,1997.

Catalogue of Janatics pneumatic product, Janatics Private Limited Coimbatore.

Design data book – compiled by Faculty of Mechanical Engineering, P.S.G. college

of technology, Coimbatore

Festo Didactic KG – Fundamentals of control technology, Esslingen-1998.

Festo Pneumatic Catlogue - Festo Pvt Ltd. – Bangalore.

Werner Deppert/Kurt Stoll., Cutting Cost With Pneumatics, Vogel Buchverlag

Wurzburg, 1998.